Light Liquid Sampler S Y S T E M S U P P O R T M A N U A L PNR-2LM-0(1)

Transcription

1 Light Liquid Sampler S Y S T E M S U P P O R T M A N U A L PNR-2LM-0(1)

2

3 PNR-2LM-0(1) Light Liquid Sampler System Support Manual Version

4 4 Table Of Contents Section 1 System Introduction 4 Section 2 Sample Pump and Balance Valve 8 Section 3 System Installation and Start-up 16 Section 4 DuraSite Vessel Instructions 22

5 About This Manual... 5 Introduction The purpose of this manual is to provided a step-bystep guide to the operation, installation and maintenance of your YZ Light Liquid Hydrocarbon Sampling System. It should be read by both firsttime and experienced measurement technicians who want to learn about the components and operation of the system. The manual has been organized into sections, which are summarized as follows: Section 1 - System Introduction Includes an overview of the system compo nents, a description of how the system operates, a schematic system diagram, and a system layout. Section 2 - Sample Pump and Balance Valve Section 3 - System Installation and Start up Includes detailed instruction on the proper way to install your YZ sampler. Likewise, a step-by-step start-up procedure is to guide the commissioning of the unit. Section 4 - DuraSite Vessel Instructions These sections include details of the DuraSite portable constant pressure sample vessel., operation and maintenance. YZ Systems, Inc Pollok Drive Conroe, Texas USA P: F: PNR-2lLM-0(1) Version ATEX Rev.

6 6 Section 1 System Introduction The PNR-2LM-0(1) is a sampling system designed to sample light liquid hydrocarbons. Operation of the system centers around the PNR-2 Sample Pump, and control functions that are totally customer supplied. The pump is mounted on a stainless steel panel, with a support tray for a portable sample. The pump and panel are shown in the diagram on the following page. The purpose of the YZ light liquid hydrocarbon sampling system is to capture a representative liquid sample of the pipeline product. In order for the system to function properly, a pipeline product must be single phase, liquid product. By properly adjusting both the sample size and the sample frequency, the sample vessel will fill to 80% capacity at the end of the sample period. The system operates on a simple concept. Each time the sample pump is actuated a preset volume of sample is gathered at pipeline pressure and collected into a portable sample vessel for transfer to a lab for analysis.

7 Factory Mut ual System Appr oved Pulse Input Module PIM-100 -SIG 2 Inpu t Adj. +SIG 1 Red -1 Wh ite-3 Black-5 Fact ory Mutual Sy s tem Ap p ro ved Pulse Input Module PIM-100 Input Adj. -SIG 2 +SIG 1 R ed-1 White-3 Black-5 Section 1 System Introduction DURASITE PRECHARGE IN (BY CUSTOMER) 7 MAGNETIC PICK UP SIGNAL (BY CUSTOMER) SYSTEM CONTROL ENCLOSURE POWER PI PULSED VOLTAGE OR DRY CONTACT OR DPS SIGNAL IN TO Z-65 CONTROLLER (BY CUSTOMER) S DURASITE (Sold Separate) INSTRUMENT AIR IN 100 PSI (BY CUSTOMER) PI Pneumatic Control Signal (By Customer) CNR-2 SAMPLING PUMP ISOLATION VALVE PI ROB VALVE CNR-2 PROBE SAMPLE VESSEL ISOLATION VALVE DURASITE PRODUCT LINE (BY CUSTOMER) PIPELINE L E G E N D PNEUMATIC RELIEF VALVE PRODUCT ELECTRICAL PI PRESSURE GAUGE NORMALLY OPEN VALVE Z-65 CONTROLLER NORMALLY CLOSED VALVE AIR RELAY VALVE RUPTURE DISC PRESSURE REGULATOR POWER PIM-100 S SOLENOID VALVE YZ Systems, Inc Pollok Drive Conroe, Texas USA P: F: PNR-2lLM-0(1) Version ATEX Rev.

8 Factory Mutual Input Adj. PSI -SIG IG 2 1 Red-1 White-3 Black-5 psi 8 Section 1 System Introduction 15 3/8" LIQUID TIGHT FITTING (7/16" Max. CABLE ENTRY) MODEL Z-65 TIMER System Approved PIM-100 ROB VALVE (1/4" FNPT) FILTER REGULATOR POWER Pulse Input Module PIM-100 Product In From Pump RELIEF VALVE 19 7/8" AIR RELAY VALVE PRODUCT SAMPLE OUT TO DURASITE (1/8" TUBING) (BY CUSTOMER) SOLENOID VALVE VESSEL RACK 4 1/4" 2" NOM. PIPE U-BOLT ASSY. (2) PULSED VOLTAGE OR DRY CONTACT OR DPS SIGNAL IN TO Z-65 CONTROLLER (BY CUSTOMER) ACTUATION GAS IN (BY CUSTOMER) (1/4" FNPT) 5-Way Cross PNEUMATIC SUPPLY (FROM SKID) PRODUCT OUT (TO SKID) ISOLATION VALVE ACTUATION GAS TO PUMP (PORT A 1/4" FNPT) PRODUCT IN FROM PUMP (PORT B 1/4" FNPT) FLOW SUPPLY PROBE

9 9 YZ Systems, Inc Pollok Drive Conroe, Texas USA P: F: PNR-2lLM-0(1) Version ATEX Rev.

10 10 Section 2 PNR Sample Pump The PNR-2P Sample Pump is a positive displacement plunger pump designed to be mounted directly on the pipeline. It has an adjustable displacement of 0.25 to 1.8cc and achieves proportional-to-flow sampling through adjustment of the customer supplied, and customer controlled pneumatic signal. As the plunger returns upward after completing a stroke, the pump chamber fills with product through the inlet check valve. The inlet check valve is a dart type valve designed to seat on an o-ring. The inlet check valve is spring loaded to ensure a positive seating action after every stroke. When the pump is actuated, the plunger moves downward, displacing product through the discharge check valve known as the balance valve. The balance valve automatically senses pipeline pressure and adjusts to ensure that product is not allowed to free-flow to the product vessel. When the pipeline pressure is greater than the pre-charge pressure on the accumulator vessel, the balance valve dart is pushed up against the seat and the top head of the balance valve. As the pump strokes, the pressure created in the pump chamber forces the balance valve dart off the seat, allowing product to be pumped to the accumulator vessel. Once the pump completes its stroke, the pressure across the balance valve equalizes and the dart is returned to a sealing position by its spring. In the event that the accumulator vessel pre-charge pressure is greater than the pipeline pressure, the balance valve dart and seat are pushed apart by the product pressure in the accumulator vessel. In this situation the check valve wafer located between the balance valve and the sample pump acts as a back check to prevent the escape of product previously captured in the accumulator vessel. As the pump strokes, the pressure created in the pump chamber forces the check valve wafer off the seat, allowing product to be pumped to the accumulator vessel. Once the pump completes its stroke, the pressure across the check valve equalizes and the wafer is returned to a sealing position by its spring.

11 Section 2 PNR Sample Pump Pump Diagram 11 STROKE SCALE, 3/8" PD PUMP D PNR-2 STROKE SCALE IND B PNR-2 ACORN NUT B /16-24 JAM NUT SS C PNR-2 STROKE SCREW ASSY B /16-18 x 5/8" HHCS SS C /16 FLAT WASHER, SS C ACTUATION SUPPLY PNR-2 PACKING GLAND NUT B PD PUMP PACKING A MCONN, 1/4T 1/8P, SS A PNR-2 ACTUATOR CYLINDER B PNR-2 PNEU ACT PISTON B /8-24 JAM NUT, SS C EXHAUST FILTER, 1/8" SS C PNR-2 UP/MID/CV BODY ASSY B PNR-2 PLUNGER BUSHING 3/8 A SEAL W/SS SPRING TFE/GLASS/MOLY 3/8" ID A PNR-2 UP/MID/CV BODY ASSY B /8" ALLEN HEAD PLUG SS A LPR/PNR INLET CHECK DART B OR -010, NITRILE A INLET CV SPRING PNR-2 C OR -210, NITRILE A FLAT WASHER SS C x 3/16 PAN HD SS C /8" SS PLUG A U-CUP WIPER SEAL (PNR-2 ACT PISTON) A /8 STAR WASHER (EXT) SS C PNR-2 3/8 CERAMIC PLUNGER B /4-28UNF x 1/2" BHCS SS (3) PNR-2P PLUNGER RTN SPRING CAD PLATED C PRODUCT OUT MCONN, 1/8T 1/8P, SS A PNR-2 CHECK VALVE FOR USE W/ BV-200 B VALVE, PURGE, SS 1/8" NUPRO A BV-200 ASSY (STD) B PNR-2 UP/MID/CV BODY ASSY B /8" 316 SEAMLESS.035W C MCONN, 1/8T 1/8P, SS A PRODUCT IN YZ Systems, Inc Pollok Drive Conroe, Texas USA P: F: PNR-2lLM-0(1) Version ATEX Rev.

12 12 Section 2 PNR Sample Pump Balance Valve Diagram P/N B2-1529

13 13 YZ Systems, Inc Pollok Drive Conroe, Texas USA P: F: PNR-2lLM-0(1) Version ATEX Rev.

14 14 Section 3 Installation/Start-up/Operation Panel Installation The sampling system should be located as close as possible to the pipeline. 2" U-bolt assemblies are provided to mount the panel to a 2" vertical pole. Pneumatic Supply A 1/4" connection on the Pump is provided for a pulsed pneumatic supply (40-60 psi). The necessary regulators, solenoid valve, control functions, etc. are customer provided. The pneumatic pulse to operate the sampler typically will require 2-3 second dwell time to assure proper pump operation. 2" NOM. PIPE U-BOLT ASSY. (2) PULSED VOLTAGE OR DRY CONTACT OR DPS SIGNAL IN TO Z-65 CONTROLLER (BY CUSTOMER) ACTUATION GAS IN (BY CUSTOMER) (1/4" FNPT) 4 1/4" 5-Way Cross Pump Installation The PNR-2 sample pump is designed to be mounted directly to a threaded connection on the pipeline. The probe tubing should be cut such that the tip of the probe will be located in the center 1/3 of the pipeline after installation. After the pipeline has been depressurized, the threads on the probe body should be taped and doped and the pump installed into the pipeline connection. Next you must install 1/4" stainless steel tubing between the connection top of the pump, to the source of the pulsed pneumatic actuation, upplied by the customer. Finally connect 1/4" stainless steel tubing from the discharge connection of the pump balance valve to the connection for product in from pump on the 5-way cross. ACTUATION GAS TO PUMP (PORT A 1/4" FNPT) PRODUCT IN FROM PUMP (PORT B 1/4" FNPT) PNEUMATIC Pneumatic Supply SUPPLY (By Customer) (FROM SKID) ACTUATION GAS TO PUMP PRODUCT FROM PUMP PRODUCT OUT (TO SKID) ISOLATION VALVE SUPPLY PROBE FLOW

15 Section 3 Installation/Start-up/Operation 15 Pump Sample Size The sample size is adjustable from 0.25 to 1.8 cc/ stroke. The sample size is adjusted by loosening the lock/seal nut on top of the pump and turning the volume adjustment screw in to decrease the sample volume or out to increase the sample volume. Once the new sample size has been set, the lock/seal nut should be retightened. Sample Pump Priming Before the pump begins normal operation after initial installation or maintenance, the sample pump must be purged of all air in the sample chamber. The purge valve on the sample pump is used to evacuate the air from the chamber and to make sure the pump is liquidpacked. If the pump is not purged before being placed into operation, it will not function properly. To purge the pump, open the purge valve located on the left side of the sample pump balance valve. The product supply valve can then be opened to allow pipeline product to purge the air within the pump. Once product begins exiting the purge valve, close the purge valve. The sample pump is now ready to begin operation. YZ Systems, Inc Pollok Drive Conroe, Texas USA P: F: PNR-2lLM-0(1) Version ATEX Rev.

16 16 Section 3 Installation/Start-up/Operation Z-65 Controller Set Up Proportional To Time Mode Calculating Time- Sample Volume Desired Pump Displacement = # of Pump Strokes Required/Sample Cycle Number of Minutes/Sample Cycle = Time in Minutes Between Strokes #of Pump Strokes Required/Sample Cycle Example 400 cc(500cc DuraSite filled to 80% Volume).25cc Pump Displacement/Stroke = 1600 Pump Strokes Required/Sample Cycle 10,080 (Minutes in Week) 1600 Pump Strokes Required/Sample Cycle = 6.3 Minutes Between Strokes (Round up to the next whole minute.)

17 Section 3 Installation/Start-up/Operation 17 Z-65 Controller Set Up Proportional To Flow Mode Sample Vessel Size x 80% = Grabs Required/Sample Cycle. Sample Grab Size ie: 500cc Vessel x 80% = 400cc = 444 Grabs Required.9 cc/grabie Pulse/Metered Volume x Monthly Average Flow = Pulses/Sample Cycle ie: 1 Pulse/BBL x 15,000 BBL/Month = 15,000 Pulses/Sample Cycle Pulses/Sample Cycle Grabs Required = Pulses/Grab ie: 15,000 Pulses/Sample Cycle = Pulses/Grab 444 Grabs Required YZ Systems, Inc Pollok Drive Conroe, Texas USA P: F: PNR-2lLM-0(1) Version ATEX Rev.

18 18 Section 4 DuraSite Portable Sample Vessel Instructions Purpose: The DuraSite Portable Sample Vessel permits the user to remove a liquid or gas hydrocarbon sample from a pipeline or a sampling device. This is accomplished without changing the pressure of the product or exposing it to a contaminant fluid. If properly used and maintained the DuraSite will provide many years of safe, accurate and clean sampling. Use: The DuraSite is a very safe device to use. As with any equipment dealing with flammable products, it is mandatory that a good, thorough operator training procedure be established prior to use. Typical use of the cylinder would be as follows: Step 1: (In The Lab) Connect a regulated inert gas supply to the pre-charge valve. The product valve should be open. By carefully controlling the pre-charge valve and the regulator, the cylinder can be slowly charged with pre-charge gas (NOTE: This should be done slowly to prevent slamming the piston down to the opposite end). The pressure on the pre-charge pressure gauge should be brought to a reading of psi above the expected pressure of the product in the field. Close the pre-charge valve and disconnect the gas supply. Check the pre-charge valve, relief device, and the pre-charge pressure gauge for leaks. Any leaks should be stopped before continuing. The vessel should be placed in a padded carrying case and made ready for field use. Proceed to EITHER Step 2, or Step 3 as required for your application. STEP 2: FOR COLLECTION OF SAMPLE VIA SPOT SAMPLE OR FROM COMPOSITE ACCUMULATOR VESSEL. 2a: Connect the product end of the pre-charged sample vessel to the product supply. (Sampler product removal valve, or Pipeline sample probe) NOTE: the pre-charge pressure gauge reading should be greater than the product supply pressure reading. If not, repeat Step 1 above. 2b: Once the vessel is connected to the product supply, it is necessary to vent a small amount of product prior to filling the vessel. This assures fresh product and removes any air or gas when dealing with liquids. This can be done by loosening the product purge valve a very small amount until the product is purged. After thorough purging, the product purge valve should be tightened. 2c: The product pressure gauge reading should be psi below the pre-charge pressure gauge reading. By carefully opening the pre-charge valve, the pressure becomes equalized, then begins to drop below the product pressure. The pre-charge valve should be carefully controlled so as to not vent the precharge gas too fast. 2d: When the cylinder becomes a maximum of 80% full (see volume indicator), all valves should be closed. The product connection is slowly broken in order to vent any trapped product. After vessel removal, all connections should be checked for leaks and the pre-charge and product valve ports capped to prevent leakage. STEP 3: FOR DIRECT CONNECTION TO SAMPLER. 3a: Connect the sampler discharge port to the product inlet port to the DuraSite using 1/8" stainless steel tubing. 3b: (Gas sampling) Connect the pre-charge port to the DuraSite to the pipeline for pre-charge pressure (Proceed to step 3d), or configured like the liquid sample application below. (Step 3c) 3c: (Light sampling) Pre-charge the DuraSite as indicated in Step 1, then install a pressure relief valve to the pre-charge port and open the pre-charge valve on the DuraSite. (The pressure relief valve should have a relief pressure setting of approximately 100 psi above line pressure.) 3d: Open the product inlet valve of the DuraSite and the purge valve on the sampler. Next open the purge valve on the product end of the DuraSite and allow product to purge all lines and connections out. 3e: Close purge valves and begin sample cycle. 3f: At the end of sample cycle, close product inlet valve on the DuraSite and remove the DuraSite. Pack the DuraSite in appropriate carrying case to meet D.O.T. guideline, with D.O.T. paperwork and transport to lab for analysis. Step 4: (In The Lab) Prior to analysis, the product should be mixed. This is accomplished simply and efficiently by inverting the cylinder end-over-end, causing the mixing ball to fall through the product. Approximately trips of the mixing ball through the product assures a homogenous solution. Step 5: The regulated pre-charge gas should be reconnected to the pre-charge side of the cylinder. The pre-charge gas supply should remain open during analysis. Step 6: Purging a small amount of product from the vessel removes unmixed product from the tee, relief device, gauge, etc. The unit can now be connected to a chromatograph and the product analyzed. Step 7: After analyzing, the remainder of the product should be dumped and the vessel properly cleaned. Normal cleaning can be accomplished by rinsing the product end with a petroleum solvent and flushing with acetone. If a more thorough cleaning is required, the vessel should be disassembled. WARNING: A portable sample vessel should never be filled to more than 80%. This allows a 20% pre-charge cushion to absorb thermal expansion of the product. Shipping: Extreme care should be taken when preparing a vessel for shipment. Both valves should be capped to prevent possible leakage. The vessel should be placed in a snug-fitting, well-padded and durable case. All applicable DOT regulations should be adhered to. 2e: Pack the DuraSite in appropriate carrying case to meet D.O.T. guideline, with D.O.T. paperwork and transport to lab for analysis.

19 Section 4 DuraSite Portable Sample Vessel Instructions DuraSite (illustrated) Valve Seat P/N A Purge Valve Nut P/N A YZ UniValve Product Head P/N C Stainless Steel Hex Nuts P/N C Back-Up Washer P/N A5-4222B O-Ring P/N A Gauge P/N A Magnetic Volume Indicator P/N C (DS-150) P/N C (DS-300) P/N C (DS-500) P/N C (DS-800) P/N C (DS-1000) Mixing Ball P/N C Piston Seal P/N A Magnet Assembly P/N (Ser. #0613 and Prior) P/N (Ser. # #4607) P/N C (Ser. #4608+) O-Ring P/N A Snap Ring P/N C Cylinder P/N C (DS-150) P/N C (DS-300) P/N C (DS-500) P/N C (DS-800) P/N C (DS-1000) Piston Washer P/N C Piston P/N (Ser. #0321 and Prior) P/N (Ser. # #0613) P/N (Ser. # #4087) P/N C (Ser. #4088+) Tie Rod P/N C (DS-150) P/N C (DS-300) P/N C (DS-500) P/N C (DS-800) P/N C (DS-1000) Set Screw P/N C Knob P/N A Rupture Disc Nut P/N A Rupture Disc P/N A YZ UniValve Pre-Charge Head P/N C Valve Seat P/N A Seat Retaining Washer P/N A Valve Stem Assembly P/N A YZ Systems, Inc Pollok Drive Conroe, Texas USA P: F: PNR-2lLM-0(1) Version ATEX Rev.

20 20 Notes

21 Notes 21 YZ Systems, Inc Pollok Drive Conroe, Texas USA P: F: PNR-2lLM-0(1) Version ATEX Rev.

22 3101 Pollok Drive Conroe, Texas P: F: Em: Web: YZ Systems, Inc. represents and warrants that for a period of 3 years from receipt of the product: (1) the product will be free from defects in materials and workmanship; and (2) the product will perform substantially in accordance with product manuals, literature, or documentation. Any written or oral information or advice given by YZ representatives, agents, or employees will in no way increase the scope of this warranty. If the product fails to comply with the warranty set forth herein, YZ's entire liability and the customer's exclusive remedy will be replacement of the product(s) or, at YZ's option, YZ's reasonable effort to make the product meet the warranty set forth herein. YZ disclaims all other warranties, either expressed or implied, including but not limited to, implied warranties or merchantability and fitness for a particular purpose, with respect to the product. This limited warranty gives you specific legal rights. You may have others, which vary from state to state. These remedies are not available outside of the United States and Canada. In no event shall YZ or its suppliers be liable for any damages whatsoever (including, without limitation, damages for loss of profits, business interruption, loss of information, or other pecuniary loss) arising out of the use of or inability to use the product, even if YZ has been advised of the possibility of such damages. Information contained in this document is subject to change without notice and does not represent a commitment on the part of YZ Systems, Inc. All prices quoted are in U.S. dollars, F.O.B. Snyder, Texas. NJEX is a trademark of YZ Systems, Inc. All other product names and/or registered trademarks are the property of their respective holders. YZ support services are subject to YZ's then-current prices, terms, and conditions, which are subject to change without notice. All prices and specifications, if published, are subject to change without notice.